Weep protection system

ABSTRACT

A combination through-wall masonry flashing/drainage device having a flashing membrane with at least one reinforcing cloth adhered to at least one side of the flashing membrane. A wicking cloth made of a synthetic wicking material is then adhered to the device. The wicking cloth material is selected for wicking ability, life expectancy, mildew resistance, and strength characteristics.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation in part application of Ser. No. 13/022,492 filed on Feb. 7, 2011, which is a Continuation application of Ser. No. 10/710,845, filed on Aug. 6, 2004, now U.S. Pat. No. 7,900,404, which claimed the benefit of U.S. Provisional Application No. 60/481,191, filed Aug. 7, 2003, all of which are entirely incorporated herein by reference.

BACKGROUND

1. Field of Invention

The invention is related to cavity wall drainage systems for masonry.

2. Description of the Related Art

Traditionally, a masonry cavity wall is constructed having an inner back-up wall made of concrete, masonry block, brick, wood or steel frame construction, and an outer veneer wall of brick, stone, block, stucco, or other masonry. The two walls are separated by an air space or cavity. The width of this cavity can be specified by building code or architectural design preference. The purpose of this type of design, two walls separated by a cavity, is to prevent water from reaching the interior of the building as well as for its insulation value. As water penetrates the outer wall or “wythe”, it collects and condenses on the inner face of the outer wall. It runs down this surface to a point where its downward flow is interrupted by a horizontal plane such as a window, door, shelf angle, lintel, or the base of the wall itself. At these points, the water is diverted out of the wall by the through-wall flashing and weep devices which are placed in such a manner as to maximize the evacuation of the water. Weep devices can be metal or plastic tubes, ropes, and other devices.

Ideally, the flashing is affixed to the back-up wall by any of several methods. One method is to insert the flashing into a horizontal joint, if the back-up wall is a masonry block wall. Another method is to insert the flashing into a reglet, which is a horizontal slot placed in a poured concrete back-up wall. Yet another method is to mechanically fasten the flashing to the backup wall with screws and a termination bar. A termination bar is a strip of metal or plastic with evenly spaced holes for screws designed to spread the load evenly across the width of the bar. This may be used on any kind of back-up wall.

The flashing runs down the face of the back-up wall to a horizontal ledge or shelf. Then it turns and runs horizontally out and through the brick veneer, forming a continuous sheet that guides any water out of the wall and prevents any water from reaching the interior of the building. This flashing was traditionally made of heavy gauge copper or lead sheet that required trained metal workers to install correctly. Laps and seams needed to be soldered, which is difficult to do properly and in a watertight fashion.

One solution to this problem is disclosed in U.S. Pat. No. 2,005,221, which is not admitted to being prior art by its inclusion in this Background section. In that patent, a copper flashing is provided with a waterproofed fabric adhered to it. However, it cannot wick water away because it is waterproof by definition.

Another problem that appears in through-wall flashing/cavity wall construction is that, as the wall is built, excess mortar from subsequent layers of brick falls into the cavity and blocks the weep openings or ropes, which can render these very important components of this system inoperable. One solution to this problem was disclosed in U.S. Pat. No. RE36,676, which is not admitted to being prior art by its inclusion in this Background section. The solution to place something in the cavity that would allow water to migrate through to the weeps, yet prevent mortar and debris from clogging these openings. Other solutions, like using pea-stone gravel or a plastic mesh unit, are still in use today.

These cavity filling devices, both gravel and plastic, have deficiencies. The gravel is heavy and difficult to transfer to higher levels of scaffolding, which leads to it being omitted. There are also claims that, because of its density in the cavity, it allows the mortar to fill up the cavity, thereby defeating the purpose. The plastic mesh products, commonly marketed under the MORTAR NET and MORTAR BREAK trademarks, are quite expensive, often costing more than the flashing itself.

This has led to the need for a product that eliminates the need for other products, is easy to install, and performs as well or better as other products which, when combined, serve the same purpose, that of allowing the free flow of water from a masonry wall cavity.

SUMMARY

The new product combines the durability, flexibility, and ease of installation of traditional copper fabric flashing, with an attractive drainage method, namely a thin, virtually invisible and effective cavity drainage system. All of this is provided in a single, easy to install, relatively inexpensive product.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 shows the components of a multiple layer combination flashing and drainage system according to the present invention.

FIG. 2 shows an alternative embodiment of the system of FIG. 1 that is used only for drainage.

FIG. 3 is a cut-away view of a masonry wall showing how the invention is used.

FIG. 4 is a cut-away view of a masonry wall showing how the alternative embodiment of the invention is used.

DETAILED DESCRIPTION OF DRAWINGS

The invention is a combination through-wall masonry flashing/drainage device 10. Turning to FIG. 1, a single sheet of flashing membrane 12 is preferably at the core of the device 10. Examples of suitable flashing membrane material include, without limitation, copper, PVC, polyethylene, and stainless steel sheet. The sheet of flashing membrane, if copper is used, preferably conforms to ASTM B-370, weighs 3 to 7 ounces/square foot, and is between 0.0036 inches and 0.0094 inches thick.

A first reinforcing cloth 14 is adhered to a first side of the flashing membrane 12 using an adhesive 16. The adhesive 16 is preferably a hot-melt type of adhesive, and is either rubber or latex. The reinforcing cloth 14 is preferably made of fiberglass and can be woven or non-woven, but preferably weighs between 0.2 and 0.3 ounces/square foot. Other natural or synthetic fabrics could also be used instead of fiberglass.

Optionally, a second reinforcing cloth 17 may be provided and adhered to a second side of the flashing membrane 12 with a layer of adhesive 16. The second reinforcing cloth 17 would be the same material as the first reinforcing cloth 14. The purpose of the reinforcing cloth 14, 17 is both to reinforce and protect the flashing membrane during installation, and to provide a rough textured surface that promotes bonding in the mortar joint.

A wicking cloth 50 is provided and adhered to the second side of the flashing membrane 12 with an adhesive 16. If a second reinforcing cloth 17 was provided, then the wicking cloth 50 is adhered to the outside of the second reinforcing cloth 17. Otherwise, the wicking cloth is adhered directly to the flashing membrane 12 with a layer of adhesive 16. The wicking cloth 50 is made of either polyester, polypropylene, polypropylene nylon, or polyethylene. The material preferably 0.050 inches thick, and weighs between five and seven ounces/square yard. The wicking cloth 50 can be either woven or non-woven. A synthetic fiber material is preferred for long life, mildew resistance, and strength. The primary criterion is the cloth has suitable wicking characteristics.

Materials and devices used previously do not have wicking material that runs the length of the front joint of an outside wall, as the present invention does. The previous materials and devices relied only on gravity to transport water from between an inside and outside wall through weep vents in the outside wall. The present invention uses wicking in addition to gravity to transport water through the mortar joint without a weep vent. To emphasize the technical difference between the two liquid transport methods, wicking is the absorption of liquid into a material by capillary action. Wicking is also known as fiber tow infiltration.

This product would preferably be manufactured as a continuous web on a double-sided, extrusion slot-die, coater/laminator. The flashing membrane base material 12 is fed into the machine where it passes over the first of two slot die extruders. The adhesive 16 is extruded in a continuous sheet/film and applied through contact to one side of the membrane. The first reinforcing cloth 14 is immediately introduced and pressed into the adhesive 16 by a series of rolls. The now three-layer product continues through the machine to such a point as the opposite side passes over the second slot die. Adhesive 16 is extruded and the second cloth, either reinforcing or wicking, and is applied in the same manner as the first, but to the opposite side of the flashing membrane 12. If a third layer of cloth 50 is to be applied, i.e. two layers of reinforcing material and one layer of wicking material, the web would have to be passed through the machine a second time.

As an alternative, the product could also be made as a self-adhesive product, combining a self-adhesive roofing underlayment style membrane with the wicking fabric on the outer surface. This roofing underlayment would be best described in ASTM standards D 6164-00 and D 1970-01 with the “top surface” being the wicking fabric.

In some scenarios, where the primary goal is to drain the cavity between the inner wall and the outer wall, the additional flashing provided by the combination through-wall masonry flashing/drainage device 10 is unnecessary. For a pure drainage system, only the wicking fabric layer 50 is needed. For example, FIG. 2 shows a drainage device 110 that is made of a sheet of the wicking fabric 50.

FIG. 3 shows an example of how the device 10 can be used. A two-inch cavity structure 44 has an upstanding front brick wall 34 and a back concrete wall 46 supported on a horizontal concrete support 38, wherein about a two inch cavity is between the front and back walls. The through-wall masonry flashing/drainage device 10 is shown as secured in a reglet 48 of the back concrete wall 46 bonded mechanically within the reglet 48. The flashing material extends downwardly within the two inch cavity 44 and exits at the front mortar joint 42, permitting trapped water to be released to the outside of the structure without the need for vents.

FIG. 4 shows an example of how the device 110 can be used. A two-inch cavity structure 144 has an upstanding front brick wall 134 and a back concrete wall 146 supported on a horizontal concrete support 138, wherein about a two inch cavity is between the front and back walls. The through-wall drainage device 110 is shown as secured in a reglet 148 of the back concrete wall 146 bonded mechanically within the reglet 148. The sheet of wicking fabric 50 extends downwardly along the back wall 148, then horizontally across the support 138 within the two inch cavity 144 and exits at the front mortar joint 142, permitting trapped water to be released to the outside of the structure. By passing through the front mortar joint 142, additional vents do not need to be drilled into the front wall 134. The wicking fabric 50 actively wicks water out of the cavity. Additionally, even if mortar droppings, dirt, debris, and fins from wall construction should fall into the cavity, the wicking fabric 50 will still direct water out of the cavity. Another advantage is that by being arranged along the back wall 148 and the support 138, the drainage device 110 does not compete for space with insulation products that are to be placed in the cavity. The drainage device 110 also acts as an insect barrier to prevent insects from entering the cavity.

While there have been described what are at present considered to be the preferred embodiments of this invention, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the invention, and it is, therefore, aimed to cover all such changes and modifications as fall within the true spirit and scope of the invention. 

1. A drainage system comprising: a wall support disposed horizontally on the ground; an first masonry wall connected to the wall support and extending vertically from the wall support, the first masonry wall constructed and arranged to be an outer wall of a building; a second masonry wall connected to the wall support and extending vertically from the wall support, the second masonry wall constructed and arranged to an inner wall of the building; and a wicking cloth installed between the first wall and the second wall, wherein water between the first wall and second wall is drawn through a mortar joint at the base of the first wall to the outside of the first wall by the wicking action of the wicking cloth without the need for vents.
 2. The system of claim 1, wherein the wicking cloth being installed between the first wall and the second wall includes being disposed along the second wall and along wall support.
 3. A method for draining a masonry wall cavity comprising: inserting a first end of a wicking cloth into a second masonry wall, the second masonry wall connected to a horizontal wall support and extending vertically from the horizontal wall support, the second masonry wall constructed and arranged to an inner wall of a building; and inserting a second end of the wicking cloth into a first masonry wall, the second end of the wicking cloth being opposite to the first end of the wicking cloth, the first masonry wall connected to the horizontal wall support and extending vertically from the horizontal wall support, the first masonry wall constructed and arranged to be an outer wall of the building; wherein the wicking cloth inserted between the first masonry wall and the second masonry wall, draws water through a mortar joint at the base of the first masonry wall to the outside of the first masonry wall by the wicking action of the wicking cloth without the need for vents.
 4. The method of claim 3, further comprising positioning the wicking cloth along the second wall and along wall support. 